Hybrid acoustic EMI foam for use in a personal computer

• US 10,162,390 B2
• Filed: 01/15/2016
• Issued: 12/25/2018
• Est. Priority Date: 01/16/2015
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Sweet, Edward T., Guterman, Jerzy S., Farahani, Houtan R., Crosby, Justin D., Boothe, Daniel K.
• Primary Examiner(s): Cunningham, Xanthia C
• Application Number:
  US14/997,442
• Publication Number:
  US 20160212892A1
• Time in Patent Office: 1,075 Days
• Field of Search: None
• CPC Class Codes: G06F 1/1688 the I/O peripheral being integrated loudspeakers

Abstract

The described embodiments relate to an electronic assembly that includes multiple varied electrical components. In some embodiments, the electronic assembly can include electrical components susceptible to electromagnetic interference (EMI). In one particular embodiment, an antenna can be positioned along an exterior surface of an enclosure of the electronic assembly and another electrical component can be disposed within the enclosure. When the other electrical component is a speaker component, a port or opening for emitting audio output can be protected from EMI by surrounding the port with a conductive gasket that includes a closed cell foam substrate wrapped in an electrically conductive fabric. In some embodiments, the closed cell foam substrate defines a number of perforations that are plated with an electrically conductive material.

Claims

1. An audio assembly, comprising:

an assembly housing comprising walls that define a port, wherein at least one wall of the assembly housing has an opening defined by the port;

an audio speaker positioned in the port; and

a gasket comprising a foam ring and an electrically conductive fabric at least partially surrounding the foam ring, the gasket positioned on the assembly housing and surrounding the opening,

wherein the gasket shields the audio speaker from electromagnetic interference (EMI) generated externally to the assembly housing.

2. The audio assembly of claim 1, wherein the gasket comprises:

a hole extending through the foam ring; and

a plated surface defining an inner surface of the hole, the plated surface formed from an electrically conductive material, the plated surface preventing the EMI from passing through the hole.

3. The audio assembly of claim 2, wherein a portion of the foam ring remains uncovered to define an uncovered portion of the foam ring, and wherein the hole and the plated surface are positioned in the uncovered portion.

4. The audio assembly of claim 1, further comprising an antenna positioned outside of the assembly housing on the walls, wherein the walls comprise:

a first wall through which the opening is formed; and

a second wall different from the first wall, wherein the antenna is positioned on the second wall, and wherein the gasket shields the audio speaker at the opening from the EMI caused by EM energy from the antenna.

5. The audio assembly of claim 4, wherein the assembly housing is formed of non-conductive material and wherein portions of the assembly housing are covered with conductive material that shields portions of the assembly housing from the EMI emitted by the antenna.

6. The audio assembly of claim 4, wherein the audio speaker further comprises a magnet that emits a magnetic field, and wherein the gasket blocks the magnetic field emitted by the magnet from passing through the gasket and interfering with the antenna when the antenna is active.

7. The audio assembly of claim 1, wherein the audio speaker comprises an acoustic membrane covering the port, and wherein the acoustic membrane is non-electrically conductive.

8. A portable electronic device, comprising:

an enclosure comprising a plurality of openings, the enclosure defining an internal volume;

an assembly housing disposed in the internal volume, the assembly housing comprising a first wall and a second wall, the assembly housing further defining an audio port that defines an opening that is aligned with the plurality of openings;

an audio transducer positioned in the audio port;

an antenna disposed on the first wall, the antenna external to the audio port; and

a gasket disposed on the second wall, the gasket comprising a foam ring and an electrically conductive fabric at least partially surrounding the foam ring and engaged with an interior surface of the enclosure, wherein the gasket surrounds the opening and engages the enclosure, wherein the gasket defines an acoustic pathway from the audio transducer to the plurality of openings, and wherein the gasket further defines a shield from electromagnetic interference (EMI) caused by EM energy emitted by the antenna.

9. The portable electronic device of claim 8, wherein the gasket further comprises:

a hole extending through the foam ring; and

a plated surface defining an inner surface of the hole, the plated surface formed from an electrically conductive material, the plated surface preventing the EMI from passing through the hole.

10. The portable electronic device of claim 8, wherein:

the enclosure comprises a top case and a bottom case, the top case and the bottom case formed from a metal,

the top case comprises the plurality of openings, and

the bottom case comprises internal walls that receive the assembly housing.

11. The portable electronic device of claim 10, further comprising a mask extending from the top case, wherein the top case and the bottom case define an opening that allows the antenna to communicate with a device external with respect to the enclosure, and wherein the mask at least partially hides the antenna.

12. The portable electronic device of claim 8, wherein the enclosure further comprises:

a display housing that carries a display monitor;

a base portion rotatably coupled with the display housing, the base portion comprising a top case, wherein the plurality of openings are formed in the top case; and

a keyboard assembly and a touch pad, the keyboard assembly and the touch pad carried by the base portion.

13. A method for forming a portable electronic device having an enclosure and an antenna, the method comprising:

providing a conductive gasket comprising;

a substrate comprising a foam ring, and

an electrically conductive fabric at least partially surrounding the foam ring;

securing the conductive gasket to an assembly housing, the assembly housing comprising walls that define a port that receives an audio speaker, wherein at least one wall has an opening that is defined by the port;

securing the antenna with the walls, wherein the antenna is external with respect to the port; and

engaging the conductive gasket with the enclosure, wherein the conductive gasket surrounds the opening and shields the audio speaker from electromagnetic interference (EMI) caused by EM energy emitted by the antenna.

14. The method of claim 13, wherein the audio speaker comprises a magnet that emits a magnetic field, and wherein the conductive gasket blocks the magnetic field emitted by the magnet from passing through the conductive gasket and interfering with the antenna when the antenna is active.

15. The method of claim 13, wherein providing the conductive gasket comprises:

covering only a portion of the substrate with the electrically conductive fabric to defined an exposed end of the substrate that is free of the electrically conductive fabric.

16. The method of claim 15, wherein the foam substrate comprises a hole, and wherein the hole comprises a plated surface formed from an electrically conductive material.

17. The method of claim 16, wherein the hole is positioned in the substrate proximate the exposed end of the substrate.